Emulsifying

Emulsifying is the process of mixing two liquids that are difficult to mix. The main focus of emulsifying is the dispersion of the discontinuous phase into preferably fine droplets. Rotor-stator machines are particularly well-suited for emulsifying tasks. The combination of high shearing and expanding forces in the mixing head allows for very fine droplets. High turbulences also enable rotor-stator machines to contribute to a quick transport of emulsifier molecules to the newly-formed surfaces.

Numerous medical ointments, cosmetic products, milk, mayonnaise, and dressings are emulsions. The emulsifying process can be visualized by looking at mixing water with oil, or fat. How do you mix oil and water? Even after intensive stirring for a long period of time, the oil swims at the water's surface once again. The energy input is important here, but also the employed technology, the emulsifying.

Emulsions are usually stabilized by emulsifiers such as tensides, which are mixed into one of the two phases before emulsifying. Emulsifiers are one part water-loving (hydrophilic) and one part fat-loving (lipophilic). One side of the emulsifier molecule bonds with the water and the other one with the oil. In this manner, emulsifiers stabilize the produced droplets and therefore counteract a segregation of the emulsion. IKA offers innovative mixing techniques for emulsifying that are suitable for the production of many different kinds of emulsions:

• Emulsifying with the ULTRA-TURRAX dispersing machines in batch processes
• Continuous emulsifying with the Series 2000 rotor-stator dispersing machines
• Continuous emulsifying with the HPH high-pressure homogenizer
• Emulsifying in recirculation processes

IKA's advanced emulsifying technology ensures the reduction degree that is adapted to each individual application. Emulsifying with IKA machines also guarantees a tight particle size distribution and long-time stability of the produced emulsions.

IKA inline machines for emulsifying are especially energy-efficient. Mixing energy is concentratedly fed into a comparatively small working area and takes effect on the product flow. This way the particularly high local energy input can be realized when emulsifying with inline machines. At the same time the installed power will optimally be used.

IKA plants with the built-in, patented DBI dispersing machine are an outstanding solution for any emulsifying process. The pre-mixing, droplet break-up, and feeding of emulsifiers and additives are all combined into one machine.


Our solutions:

Inline dispersers / Mills

	Type	Description	Application
	ULTRA-TURRAX UTL	Single-stage dispersing machine	Production of coarse emulsions and suspensions
	DISPAX-REACTOR DRS	Two-stage high shear dispersing machine with highest shear rates	Production of finest micro-emulsions
	Colloid Mill MK	Colloid mill	Production of extremely fine suspensions and emulsions
	Cone Mill MKO	Cone mill	Production of extremely fine suspensions
	DISPAX-REACTOR DR	Three-stage high shear dispersing machine	Production of macro-emulsions and fine suspensions
	UTL Economy Line	Single-stage dispersing machine of Economy line	Production of coarse emulsions and suspensions

Batch dispersers

	Type	Description	Application
	ULTRA-TURRAX UTE	High shear dispersing machine for bottom entry	Production of emulsions and suspensions
	ULTRA-TURRAX UTC	High shear dispersing machine for top entry	Production of emulsions and suspensions
	ULTRA-TURRAX UTS	High shear dispersing machine in the pharma design for top entry on vessels	Production of emulsions and suspensions

Process plants

	Type	Description	Application
	Dilution plant	Delution plant	Continuous mixing or also dilution of different free-flowing mediums
	Turnkey plants	Individual turnkey systems with proven IKA® mixing technology	Manufacture of mixtures of all kinds
	Standard Plant SPP	Universal mixing plant, consisting of vessel, agitator, dispersing machine and electric control	Efficient mixing, dispersing and optimal feeding of additives during production of emulsions and suspensions
	Master Plant MP	Universal mixing plant, consisting of vessel, agitator, dispersing machine and electric control with HMI	Efficient mixing, dispersing, heating/cooling and optimal feeding of additives during production of emulsions and suspensions

Solid-liquid mixers

	Type	Description	Application
	DBI (recirculation)	Machine for suction of liquid and solid components, pumping and dispersing in recirculation process	Production of emulsions and suspensions
	DR-PB (PMB)	Inline machine for mixing of solids and liquids at highest requirements regarding the dispersing quality	Continuous incorporation of polymers into hot bitumen

Pilot plants

	Type	Description	Application
	magic PLANT	Laboratory scale process plant for batch wise mixing and emulsifying of low viscous masses up to masses just about capable of flowing.	Great variety of applications. It is especially suited for processing of products from the cosmetics, food and pharmaceutical industries.
	PROCESS-PILOT	Machine with different modules, applicable in laboratories and pilot plant stations, for process optimisation, determination of process parameters and further scale-up	Mixing and dispersing in continuous and discontinuous process, also at higher temperatures, under pressure and vacuum
	LABOR-PILOT	Machine with different modules, applicable in laboratories and pilot plant stations, for process optimisation, determination of process parameters and further scale-up	Mixing and dispersing in continuous and discontinuous process
	magic LAB	Laboratory machine for product development and process optimisation with different modules and mounting possibilities	Mixing and dispersing in continuous and discontinuous process